Process of making sound absorbing material



vv. A. McMlLLAN 2,087,064

PROCESS 0F MAKING lSOUND ABSORBING MATERIAL 'July 13,

original Filed oct. 19, 1955 I y.. 111111 111111.- 11111A 1 11 1111111 11 11 1 111111 auf l 4 lll/ l/ l l//l/ l l A. l l u 1.2',

Patented July 13, 1937 PROCESS OF MAKING:` SOUND ABSORBING MATERIAL William A. McMillan, Milwaukee, Wis., assignor to Burlington Mills, Incorporated, Burlington, Wis., a corporation of Wisconsin Original application 4October 19, 1935, Serial No, 45,695, .now Patent No. 2,034,588. Divided and this application January 23, 1936, Serial No.

This invention relates to a process of producing anew and improved insulating and sound absorbing material characterized as comprising a.

felted sheet or strip having a finished, decorative surface of pleasing and ornamental appearance which is adapted for various uses, and particularly, as panels or similar pieces for lining automobile bodies and the like.

This application is a division of applicants copending application, Serial No. 45,695, iiled October 19, 1935, now Patent No. 2,034,588 and entitled Sound absorbing material and process of making same.

Automobiles -as now constructed usually have metallic bodies. Such bodies are strong, safe and generally more desirable, except for the fact that they are noise producing when the car is in motion. The motion of the car over the usual irregularities of the road causes such bodies to give off a rumbling and drumming noise which necessitates for their successful use, the application thereto of some suitable sound deadening material.

This `objection to metallic bodies, and especially metallic bodies of modern design of the streamline or semi-streamline type has retarded to some extent, the naturaland desired development of metallic bodies but the problem has now been met by theuse of certain lining materials, usually felted sheets, applied generally to the interior of a body by means of `a suitable adhesive such as asphaltic or other adhesive materials.

In addition to the sound deadening effect such lining materials alsof have the property of heat insulation, which becomes more important with metallic walls; and particularly nowwhen cars are sometimes equipped with heating and cooling devices.

Such felted materials are usually relatively cheap, formed from jute or similar fibers and as applied'to the body, leave an unsightly appearance,necessitating a further covering of a suitable nishing material such as, leather, imitationV leather, mohair or other suitable cloth or finishing material.

It will ithus be seen thatthe finishing of the usual` automobile body requires not only the application of the sound deadening felt material but also a covering material which provides the pleasing and decorative finish referred to. The finishingV material is vnot only expensive but necessitates a `separate applying operation which t adds to the manufacturing time and expense.

Further-more, with cars of modern design, there is usually provided a great deal of space, par- 8 Claims. (Cl. 154-28) ticularly in the rear compartment thereof, which is utilized for rumble seats, luggage space and similar purposes. This space likewise must be covered with sound dead-ching material andk similarly finished to providethe. desired pleasing ap- 5 pearance. Inasmuch, however, as the rear and other compartmentsreferred to, usually are not a direct part of the passenger vcompartment of the car, it is not essential to 4employ the same expensive` ni'shing materials usually applied to 10 the passenger compartment. It is only necessary to employ a material possessing the sound deadening` lproperty which itselfmay have a satisfactory pleasing nished appearance.

A material of this latter type capable of being 15- applied to the interior of the walls in a single operation, as panels if desired, without requiring an additional finishing or covering material to be applied thercover, would supply a great need in the industry and provide a solution for the 20 above enumerated problems. in a cheap and economical manner.

Accordingly, the material of this invention is v particularly adapted for such use although it may be used throughouty the entire interior of cars if such should prove desirable.

The material of this invention comprises essentially a body strip or sheet composed of a -felted, matted layer of iibers such as jute or hair bers, which have been suitably carded or combed and punched through a backing strip of burlap or other suitable material. This is a well known form of felt which is now produced in large quantities and which serves admirably as a base sheet from which the material of this invention may be made. The method of manufacture of this felt is understood and known in the art and therefore ardctailed description will, not be here given. However, it is known that the felted mat is applied to the burlap backing strip by punching the mat of fibers through the burlap by suitable needles which cause certain of the fibrous material to extend through the 'interstices of the burlap strip, and, in this manner, to become locked to the strip.

In accordance with the present invention, the felted material so prepared, while in a soft, ilexible condition, is subjected to fa printing operation, as by rollers or other suitable printing devices which apply to the burlap surface thereof, a desired marking in one or more colors and/or designs, with the result that the visual effect of the printed marking superimposed on the visible woven threads of the burlap give to the whole, the

appearance of a woven cloth of heavy and good quality and of pleasing and attractive appearance. For instance, by applying to such burlap surface, a thin diagonal slash of some desired contrasting or blending color, the natural weave of the burlap fabric together with the slash marking gives to the material an appearance somewhat similar to that of an expensive and heavy woven cloth. The markings may be of any desired type, as for instance, instead of a diagonal slash the marking may be of a herringbone or other typical style of weave, which will impart to the material, the appearance of a heavy woven cloth of desired pattern. Furthermore, an additional marking such as a relatively large plaid stripe in one or more colors may be superimposed on the first mentioned marking so as to provide an imitation of plaid or striped cloth.

Q In addition to the above markings, the appearance may be further developed by first dyeing or otherwise coloring the burlap so as to give to it a desired blending or contrasting color with respect to the printed markings to be applied thereto. In such cases the burlap backing may be dyed a color which either blends with or is in contrast to the cross slashes or other markings in the desired way to produce a desired finished appearance.

In addition to the above methods of providing desirable appearance effects, the fiber itself may likewise be colored in the same manner that the burlap strip is colored. Thus the burlap and attached fibers may be dyed or colored the same color and/or shade, or of a contrasting color and/or shade. By providing different colors for the fibers and burlap backing strip a very pleasing mixed woven fabric appearance is imparted to the material according to the selection of the colors employed. This material then lends itself well to the subsequent marking by the printing operation which imposes thereon a striped, herringbone, plaid or other effect, in one or more colors.

In this way, as a result of colors, the materials employed, the printed markings thereon, and the visible woven threads of the burlap, a large variety of very pleasing surface effects may be produced all of which simulate in appearance, the appearance of heavy and expensive woven fabrics of desirable and pleasing patterns. Such material is admirably suited for lining and finishing uses such as the lining of automobile bodies, because in addition to its finishing effect, it has good sound deadening qualities as well as the property of vinsulating against heat transfer.

After printing the material as above described and the ink applied thereto has dried, the material is next sized by the application of a suitable sizing material to the vburlap side thereof which serves the joint purpose of fixing and anchoring the projecting ends of the fibrous material punched through the interstices of the burlap and at the same time, by subsequent ironing or calendering, producing a glazed, smooth and finished appearance on the surface thereof.

This sizing and calendering imparts to the material sufficient surface hardness and rigidity to enable it to be cut into semi-stili panels of suity able shape adapted to be readily and cheaply applied to the interior walls of automobiles or the compartments thereof without additional 1inishing.

As showing a speci example of the present invention, reference may be had to the accompanying drawing in which;

Figure 1 is a perspective view of a sheet or strip of felted material of the type suitable for use in making material of this invention;

Figure 2 is a perspective view of the material shown in Figure 1, in which contrasting or blending colors are employed for the fibers and the burlap backing strip, respectively;

Figure 3 is a perspective view of the felted material shown in Figures 1 or 2 having a cross slash marking printed on the burlap surface thereof and Figure 4 is a perspective view of the material printed as shown in Figure 3 having in addition, a plaid stripe printed over the diagonal slash marking.

As shown in the drawing thev invention as here illustrated utilizes as a base material, a strip or sheet of felt I0, comprising a mat or layer of felted bers I I, which may be of jute, hair or any other suitable material of the type employed for making felt materials. This strip is provided with a backing strip I2 of burlap or other suitable fabric, preferably of a loose, open weave and relatively inexpensive in character.

Felt material of the type shown in Figure 1 is now supplied on the market and its method of manufacture is known and understood by those skilled in this art and therefore a detailed description will not be here given. However, it is known that the bers are fed upon the burlap strip and are compacted and felted by the punching action of a group of needles which in addition to felting the fibers, cause certain portions thereof to project through the interstices of the burlap backing strip. This is represented in Figure 1 of the drawing at I3.

In making this material, the bers and the backing sheet may be given the desired color by dyeing or other suitable coloring process so that a contrasting or blending color appearance may be imparted to the material. The fibers may be light on a dark background of burlap or vice versa, or both the fibers and burlap may be dyed different shades of somewhat the same color.

Of course it is to be understood also, that either the fibers or'the backing sheet may be left in its natural color and employed with' a contrasting color given to the bers or a backing strip, as the case may be. y The material prepared either with the fibers r and backing sheet of the same'color as shown in Figure 1, or of contrasting or blending colors as shown in Figure 2 and while in a soft flexible condition, is next subjected to a printing peration by means of rolls or other suitable printing device for applying thereto suitable markings such as the diagonal slash lines I5, shown in Figure 3. These slash lines are such as to impart to the material an appearance similar to that characteristic of woven fabric. In place of the diagonal slash lines, other markings, such as herringbone markings, or other typical woven patterns may be employed so that as a result, the combined appearance of the actual weave of the threads of the burlap and the slash or other `C markings placed thereon, give to the Whole, the

appearance of a woven fabric of heavy and good quality.

In addition to the printed markings above described, a further printed marking may be placed thereon such as for instance, the plaid marking I6, shown in Figure 4. This may be in a similar or dierent color from the markingv shown in Figure 3 vand in addition, the various stripes of the plaid may be in different or similar colors.

Furthermore, it is to be understood that the printing of the material may include any number of suitable marking operations in any desired combination of patterns and colors so as to give the desired finished effect which in combination with the natural weave of the burlap strip will give to the whole, the appearance of a heavy fabric.

After the printing has been completed, the material is next subjected to a drying operation after which it is next treated with a size on the burlap side thereof. Any suitable size may be employed such as latex, glue, starch, or other suitable sizing now known and used in industry, and which may be subsequently heat treated and/or ironed or calendered so as to impart to the printed burlap surface, a glazed, semi-stiff finished appearance. the sizing material, not only is the desired finish imparted to the surface but in addition, a very durable, elastic bond is formed for holding thefibrous ends I3 which project through the burlap strip. The anchoring ofthe fibrous ends through the burlap strip is also the function of anysizing material that may be employed.

From insulating and sound deadening material so produced, panels may be cut of the desired shape and size adapted to be readily applied to the interior walls of automobile bodies. Panels thus formed can be` quickly and easily applied directly to the interior Walls of the body without requiring any covering or finishing material as now employed in connection with the linings used in automobiles. The material of this invention and the panels made, therefrom have a very pleasing appearance and thus provide a suitable finish without utilizing expensive surfacing materials.

It is apparent that this material, due to its felted fibers, is an excellent sound deadening and heat insulating material which has imparted thereto, a desirable surface appearance by very simple and inexpensive manufacturing steps. This material is thus made very cheap and can be employed with a high degree of satisfaction in a number of uses where much more expensive materials are now required.

I claim:

l. The method of making a sound deadening and insulating material having a pleasing appearance which comprises the steps of felting alayer of fibrous material onto a base layer of loosely Woven fabric, whereby to cause a portion of said .fibrous material to extend 'through and protrude from said base layer, printing on the sur- L face of said base layer and on the protruding portion of said fibrous material, markings of such character as to give to said material, the appearance of a heavy woven fabric of good quality, thereafter applying size to said base layer over said printed markings and then heat treating the material so prepared. f

2. The method of making sound deadening and insulating panels for lining automobile bodies and the like, comprising the steps of felting alayer of brous material onto 4a base layer of loosely woven fabric, whereby to cause a portion of said fibrous material to extend through and protrude from said base layer, printing on the surface of said base layer and on the protruding portionI of said fibrous material, markings of such character as to give to said material, the appearance of a heavy woven fabric of good quality, thereafter sizing said base layer over said printed markings and If latex is employed as heat treating the material so prepared and finally cutting said material into panels of predetermined shape-and size.

3. The method of making a sound deadeningand insulating material having a pleasing appearance which comprises the steps of felting a layer of fibrous material onto a base layer of burlap, whereby to cause a portion of said fibrous material to .extend through and protrude from said base layer, printing on the surface of said base layer and on the protruding portion of said fibrous material, markings of such character as to give to said material, the appearance of a heavy woven fabric of good quality, thereafter applying size to saidl base layer over said printed markings and then heat treating the material so prepared;

4. The method of making sound deadening and insulating panels for lining automobile bodies and the like, comprising the steps of felting a layer of fibrous material onto a base layer of burlap, whereby to cause a portion of said fibrous material to extend through and protrude from said base layer, printing on the surface of said base layer and on the protruding portion of said fibrous material, markings of such character as to give to said material, the appearance of a heavy woven fabric of good quality, thereafter sizing said base layer over said printed markings and heat treating the material so prepared and finally cutting said material ,into panels of predetermined shape and size.

5. The method of making a sound deadening and insulating material having a pleasing appearance which comprises the steps of coloring fibrous material, felting said fibrous material onto a base layer of loosely woven fabric, whereby to cause a portion of said brous material to extend through and protrude from said base layer, printing on the surface of said base layer and on the protruding portion of said fibrous material, markings off such character as to give to said material the appearance of a heavy woven fabric of good quality, thereafter applying sizing to said base layer over said printed markings and then heattreating the materials so prepared.

6. 'Ifhe method of making a sound deadening and insulating material having a pleasing appearance which comprises the steps of coloring a base layer of loosely woven fabric, felting a layer of fibrous material onto said base layer, whereby to cause a portion of said fibrous material to extend through and protrude from said base layer,

printingon the surface of said base layer and on the protruding portion of said fibrous material, markings of such character as to give to said material, the appearance of a heavy woven fabric of good quality, thereafter applying size to said base layer over said printed markings 'and then heat treating the material so prepared.

'7. The method of making a sound deadening and insulating material having a pleasing appearance which comprises the steps of dyeing fibrous material, felting said fibrous material onto a base layer of loosely Woven fabric, whereby to cause a portion of said fibrous material to extend through and protrude from said base layer, printing on the surface of said base layer and on the protruding portion of said fibrous material, markings of such character as to give to said material the appearance of heavy woven fabric of good quality, thereafter applying sizing vto said base layer over said printed markings and' then heat treating the materials so prepared.

8. The method of making a sound deadening and insulating material having a pleasing appearance which comprises the steps of dyeing a base layer of loosely woveniabric,` felting a layer of ilbrous material onto said bas'e layer, whereby to cause a portion of said iibrous material to extend' through and protrude from said base layer, printing on the surface of said base layer and on the WILLIAM A. McMILmN. 

